Summary of the activities and main achievements (for PR2) towards the three technical objectives (TO), defined in Annex 1:
Progress towards TO 1: Advanced physics-based and adaptable battery models
During PR2, significant progress was achieved in WP2 through the completion and parameterisation of both the computationally efficient BMS model and the sophisticated cloud model. The model parameterisation was based on comprehensive experimental characterisation data generated within the project, including GITT measurements, electrochemical impedance spectroscopy (EIS), ageing tests, and half-cell analyses.
A major achievement was the successful deployment of the electrochemical model on the Infineon AURIX TC375 microcontroller. Advanced diagnostic functionalities were further developed within the cloud environment, including parameter identification from discharge curves and EIS measurements, degradation analysis based on Loss of Lithium Inventory (LLI) and Loss of Active Material (LAM), and advanced State-of-Health estimation methods. The developed diagnostic framework was successfully validated using experimental ageing data generated within NEXTBMS.
In parallel, WP2 and WP4 collaborated on preparing the integration of the developed models into the future validation environment, and virtual upscaling activities and battery pack simulations were completed.
Progress towards TO 2: Advanced data acquisition combining sensor-based solutions and model-generated information
During PR2, major progress was achieved in WP3 through the finalisation of the innovative sensor-integrated battery module concept. Multiple sensing technologies were successfully integrated into the demonstrator modules, including fibre-optic strain and temperature sensors, PT1000 temperature sensors, large-area sensing foils, piezoelectric force sensors, and electrochemical impedance spectroscopy measurement hardware.
The mechanical and electrical integration of the sensor systems was completed and validated through dedicated calibration and testing activities. In parallel, the data acquisition infrastructure and synchronised measurement software were finalised, enabling synchronized acquisition of all sensor signals.
Further progress was achieved regarding EIS-based sensing functionalities. Dedicated experimental campaigns were conducted to evaluate the suitability of EIS measurements for lithium-plating detection and thermal gradient identification under representative operating conditions. Additional test benches combining advanced EIS hardware and reference measurement systems were successfully established and operated.
At the system level, the NEXTBMS hardware architecture was finalised. This included completion of the daughter boards for cell monitoring, balancing and EIS measurements, the slave controller architecture, the AURIX-based master controller, and the battery protection electronics.
Progress towards TO 3: Advanced control algorithms, state estimation and validation of the NEXTBMS concept
During PR2, progress was achieved regarding the development of the advanced SoX functionalities. State-of-Charge (SoC), State-of-Health (SoH), and State-of-Function (SoF) algorithms were completed and verified using Model-in-the-Loop test environments. The developed algorithms combine measured signals, model-generated information, ageing corrections, and battery operating constraints to enable state estimation and control.
Cloud-based functionalities were further developed through the definition and implementation of the NEXTBMS edge-to-cloud architecture. Dedicated use cases were established for physics-based model reparameterization, Remaining Useful Life (RUL) estimation, and real-time battery data streaming. The cloud infrastructure, communication framework, and security architecture were defined and prepared for demonstrator integration.
The RUL framework was further enhanced using experimental NEXTBMS ageing data and extended towards module-level prediction capabilities. In parallel, cloud-based physics-informed degradation modelling activities progressed through the implementation and calibration of ageing sub-models.
Within WP4, comprehensive preparations for the upcoming validation phase were completed. Detailed Hardware-in-the-Loop test plans were established for both automotive and stationary applications, virtual battery pack validation was performed using the Open Vehicle Powertrain Platform, and dedicated HiL infrastructures were prepared at EDF and TNO.
